Mattress assembly

ABSTRACT

A mattress assembly includes a mattress frame comprising a base surrounded by a sidewall defining a recess. A plurality of elongate support elements are disposed in the recess. Each of the support elements has at least first and a second faces of different firmness. The elongate support elements are arranged in the recess with selected faces oriented upwardly to form an upper mattress surface having a plurality of zones of different surface firmness.

BACKGROUND

This section provides background information related to the present disclosure which is not necessarily prior art.

This invention relates to bed and bedding, and in particular to a new mattress assembly comprising a plurality of support elements that allow the user to create a mattress surface with a plurality of zones of different firmness.

There are a wide variety of mattresses designs intended to improve user comfort. Many of these designs employ mechanical, hydraulic, or fluid systems to provide customization. Other designs employ replaceable components to provide customization. In general the currently available designs for customizable mattresses are elaborate and complicate. Many require electric power. Some require a stock of replaceable parts.

SUMMARY

This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features.

Embodiments of the present invention provide a mattress of simple construction, yet whose surface can be quickly and easily customized by the user to provide a surface of customized zones of firmness.

Generally, a mattress according to a preferred embodiment of this invention comprises a mattress frame comprising a base surrounded by a sidewall defining a recess. There are a plurality of elongate support elements disposed in the recess. Each of these support elements has at least first and a second faces of different firmness. These support elements can be arranged in the recess with selected faces oriented upwardly to form an upper mattress surface having a plurality of zones of different surface firmness. The user can quickly and easily make a less firm zone firmer, or a more firm zone softer simply by turning one or more of the support elements to expose a different face. To facilitate this, at least first and second faces of the elongate support elements are marked to distinguish between the relatively firmer and relatively softer faces. This marking to distinguish between the relatively firmer and relatively softer faces preferably comprises color.

The elongate support elements are preferably the same size and shape. Each of the elongate support elements is preferably a rectangular prism, with a rectangular transverse cross section, and more preferably with a square transverse cross section.

The elongate support elements are sized and shaped so that there are at least three, and more preferably at least twelve, elongate support elements in series between the head and the foot of the mattress.

The elongate support elements preferably include a resiliently compressible foam. In the preferred embodiment each of the elongate support elements comprises at least two foam elements of different firmness forming the at least first and second faces of different firmness. Each of the elongate support elements preferably further comprises a fluid impermeable envelope surrounding the elongate support element. There is preferably at least one vent in the fluid impermeable envelope, to allow air to enter and exit the envelope. This vent is preferably variable so that the rate of air flow through the vent can be adjusted.

In an alternate embodiment the elongate support elements can include at least one valve in the fluid impermeable envelope, to allow liquid to be introduced into or removed from the envelope, and the elongate support elements include a liquid.

In some embodiments, a plurality of intermediate elements can be disposed in the recess below the elongate support elements. At least some of the intermediate elements have different firmnesses, to further enhance the variability of the firmness of the mattress.

In a double, queen, or king size mattress embodiments, the elongate support elements are preferably arranged in at least two columns, one column adjacent one side of the mattress frame, and another column adjacent the other side of the mattress frame.

The mattress assembly optionally includes a pad overlying the upper surface formed by the plurality of elongate support elements. A recloseable cover preferably enclosing the mattress frame, the plurality of elongate support elements, and the optional pad.

Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.

DRAWINGS

The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.

FIG. 1 is a perspective view of a first preferred embodiment of a mattress assembly, according to the principles of the present invention;

FIG. 2 is a perspective view of the first preferred embodiment of a mattress assembly, with portions of the frame broken away, and some of the elongate support elements removed to show details of construction;

FIG. 3 is a perspective view of an alternate construction of the first preferred embodiment of a mattress assembly, showing the optional pad;

FIG. 4 is a perspective, exploded view of a second preferred embodiment of a mattress assembly in accordance with the principles of this invention;

FIG. 5 is a perspective view of the second preferred embodiment of a mattress assembly, with portions of the frame broken away, and some of the elongate support elements removed to show details of construction;

FIG. 6 is a perspective view of an alternate construction of the second preferred embodiment of a mattress assembly, showing the optional pad and cover;

FIG. 7 is a perspective view of a second alternate construction of the second preferred embodiment of a mattress assembly, showing an alternative construction of the pad;

FIG. 8 is an enlarged perspective view of the elongate support element used in some of the embodiments;

FIG. 9 is an enlarged perspective of the elongate support element with part of its protective envelope removed;

FIG. 10 is a plan view of an adjustable vent incorporated into the elongate support element in some of the embodiments;

FIG. 11 is a transverse cross-sectional view of an alternate construction of an elongate support element

FIG. 12 is a transverse cross-sectional view of an alternate construction of an elongate support element

FIG. 13 is a transverse cross-sectional view of an alternate construction of an elongate support element

FIG. 14 is a transverse cross-sectional view of an alternate construction of an elongate support element

FIG. 15 is a transverse cross-sectional view of an alternate construction of an elongate support element

FIG. 16 is a transverse cross-sectional view of an alternate construction of an elongate support element

Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.

DETAILED DESCRIPTION

Example embodiments will now be described more fully with reference to the accompanying drawings.

Embodiments of the present invention provide a mattress of simple construction, yet whose surface can be quickly and easily customized by the user to provide a surface of customized zones of firmness.

A first preferred embodiment of mattress assembly according to the principles of this invention is indicated generally as 20 in the FIGS. 1-3. Mattress assembly 20 comprises a mattress frame 22 having a head 24 a foot 26, and first and second sides 28 and 30 extending therebetween. The frame 22 comprises a base 32 surrounded by a sidewall 34 defining a recess 36. The frame 22 can be made of a foam material, portions of which may be perforated to assist in management of heat and moisture in the mattress. The base 32 or sidewalls 34 could also include cells that can be filled with a gas or liquid to enhance the rigidity of the frame 22.

There are a plurality of elongate support elements 38 disposed in the recess 36 of the frame 22. Each of these support elements 38 has at least first and a second faces 40 and 42 of different firmness. These support elements 38 can be arranged in the recess 36 with selected faces 40,42, oriented upwardly to form an upper mattress surface having a plurality of zones of different surface firmness. The user can quickly and easily make a less firm zone firmer, or a more firm zone softer simply by turning one or more of the support elements 38 to expose a different face. To facilitate this, at least first and second faces 40 and 42 of the elongate support elements are marked to distinguish between the relatively firmer and relatively softer faces. This marking to distinguish between the relatively firmer and relatively softer faces preferably comprises color (first face 42 being shown in the Figures as being lighter than second face 44).

The elongate support elements 38 are preferably the same size and shape, although in other embodiments the elongate support elements 38 can have a variety of shapes. In this preferred embodiment, each of the elongate support elements 38 is preferably shaped like a rectangular prism, with a rectangular transverse cross section, and more preferably with a square transverse cross section. The length of each of the elongate support elements 38 is preferably with width of the recess 36 for a single mattress assembly, and half the width of the recess for a double, queen, or king size mattress assembly, thus providing each half of the mattress with its own individually adjustable zones of varying firmness. The elongate support elements 38 are sized and shaped so that there are at least three, and more preferably at least twelve, elongate support elements in series between the head 24 and the foot 26 of the frame 22.

The elongate support elements 38 preferably include a resiliently compressible foam, such as a latex or polyurethane foam. As shown in FIG. 9, In the preferred embodiments each of the elongate support elements 38 comprises at least two foam elements 46 and 48 of different firmness forming the at least first and second faces 42 and 44 of different firmness. For example foam element 46 could be a low indentation force (IDF) foam, such as a layer of a 10 IFD 4 pound Dunlop latex foam, forming the relatively softer or less firm face 42, and the foam element 48 could be a high IFD foam, such as a layer of a 16 IFD 4 lb gel memory foam, forming the relatively firmer face 44. In this preferred embodiment the elongate support element comprises the two foam elements 46 and 48 which are joined together with adhesive, heat welding, or other suitable means. Alternatively the two foam elements 46 and 48 can be coextruded, or otherwise formed together. In this two layer construction, one half of the element forms the first face 42 and one half of the element forms the second face 44.

Each of the elongate support elements 38 preferably further comprises a fluid impermeable envelope 50 surrounding and enclosing the elongate support element. The fluid impermeable envelope 55 can be a flexible, non-toxic polymeric material such as polyvinyl chloride, or other suitable material. As shown in FIGS. 8 an 9, the envelope 50 can be formed of two pieces of material joined at a central seam (such as by rf welding) so that each of the faces 42 and 44 has a different color, indicating the relatively softness or firmness of foam in that part of the elongate support element. There is preferably at least one vent 52 in the fluid impermeable envelope 50, to allow air to enter and exit the envelope. This vent 52 is preferably variable so that the rate of air flow through the vent can be adjusted. As shown in FIG. 10 one possible configuration for an adjustable vent provides two relatively rotatable disc members 54, rotating one disc relative to the other increases (or decreases) the alignment of the perforations, increasing or decreasing the rate of airflow through the vent 52, thereby adjusting the responsiveness of the elongate support elements 38 when loaded and unloaded (as when someone lays down or get up from the mattress assembly).

In an alternate embodiment the elongate support elements 38 can include at least one valve (not shown) in the fluid impermeable envelope 50, to allow liquid to be introduced into or removed from the envelope, and the elongate support elements include a liquid.

In some embodiments, a plurality of intermediate elements 56 can be disposed in the recess 36 below the elongate support elements 38. For example as shown in FIG. 2, there are four such elements 56A, 56B, 56C, and 56D from the head 24 to the foot 26 of the frame 22. For a single bed, one element 56 spans the distance from one side of the frame to the other. In a double, queen, or king size mattress, two or more elements span the width of the recess 36. The elements 56 are preferably wider than the elements 38 so that several elements 38 overlie each element 56. At least some of the elements 56A, 56B, 56C, and 56D have different firmness, so that the elements provide an additional possibility of customization and control of the firmness of the mattress for the user. For example some of the elements 56 can be made of a 13 IFD 1.6 lb polyurethane foam, forming a relatively soft element, and of a 20 IFD 1.5 lb polyurethane foam. The elements 56 could be perforated if desired, to improve air flow through the mattress, thereby aiding heat and moisture management.

The mattress assembly optionally includes a pad 60 overlying the upper surface formed by the plurality of elongate support elements 38. The pad 60 is preferably enclosed in its own jacket 64. The pad 60 can be made of a foam, such as a 16 IFD 3 lb gel memory foam, and preferably has a plurality of perforations 66 to improve air circulation. A cover 68 preferably fits over and encloses the mattress frame 22, the plurality of elongate support elements 38, and the optional pad 60. This cover 68 can have a top surface dressed similar to a conventional mattress. Alternatively can comprise a container with a hinged cover, such as disclosed in U.S. Pat. No. 6,256,821, the entire disclosure of which is incorporated herein by reference. The jacket 64 of the pad 60 and the cover 68 can be made of a temperature regulating materials, such the phase change textiles available from Outlast Technologies LLC, 831 Pine Ridge Road, Golden, Colo. 80403 USA.

While in the preferred embodiment, the elongate support elements 38 comprise foam bodies, such as latex foams, polyurethane foams, or even viscoelastic polyurethane foams—so called “memory foams”, the elongate support elements 38 can be made of other suitable materials, such as a mass of bonded polymer fibers, such as polyester fibers; gels; gas-filled chambers; fluid filled chambers.

While in the preferred embodiment the elongate support elements 38 comprises two foam bodies 46 and 48 providing two oppositely oriented faces 42 and 44 with different levels of firmness, the elongate support elements could have other constructions that provide two or more faces of different firmness. Examples of these constructions are shown in FIGS. 11-16. In FIG. 11, there are four foam bodies 102, 102, 104, and 106, forming four faces with different levels of firmness, 110. 112, 114, 116. In FIG. 12, there two blocks are 122 and 124, forming an hourglass shape, with first and second faces 126 and 128. In FIG. 13, there is a large central body 132, with blocks 134 and 136 forming faces 138 and 140. In FIG. 14 there are two blocks 150 and 152 forming a generally hourglass shape, with blocks 154 and 156 with a semicircular cross section filling in the space, forming faces 158, 160, 162, 164. In FIG. 15, blocks 170 having a wavy surface 172, and block 174 having a keyway 176, and a surface 178. FIG. 16 has blocks 182 and 184 forming an hourglass configuration, with blocks 186 and 188, forming faces 190, 192, 194, and 196.

The entire mattress assembly is preferably made of compressible or deflatable materials such that the entire assembly can be compressed and sealed in a polymeric envelope, folded, rolled, and shipped within UPS girth parameters (2×h+2×w+l)<130.

A second embodiment of a mattress assembly is indicated generally as 20′ in FIGS. 4 and 5. Mattress assembly 20′ is similar in construction to assembly 20, and corresponding parts are indicated with corresponding reference numerals. Unlike mattress assembly 20, mattress assembly 20′ does not include members 56.

An alternative construction of the second embodiment 20′ is shown in FIG. 7, and corresponding reference numerals indicated corresponding parts. However, as shown in FIG. 7, the pad 60 is not perforated.

While the sizes of the components of the mattress assembly can vary, in the preferred embodiment the components have the following sizes:

Queen Queen Queen Configuration 1 Configuration 2 Configuration 3 (No Pad) (Pad) (Pad) Frame Length 79 79 79 Frame Width 59 59 59 Frame Height 11 8.5 6.5 Recess Length 71 71 71 Recess Width 51 51 51 Recess Depth 8.75 5.75 5.75 Elongate Support 25.5 25.5 25.5 Element Length Elongate Support 5.92 5.92 5.92 Element Width Elongate Support 5.75 5.75 5.75 Element Height Intermediate 17.75 N/A N/A Element Height Intermediate 51 N/A N/A Element Width Intermediate 3 N/A N/A Element Thickness Pad Length N/A 79 79 Pad Width N/A 59 59 Pad Thickness N/A 2 2

Operation

In operation, the user opens or removes the cover and optional pad of the mattress assembly to expose the elongate support elements 38. The user can adjust the firmness of individual zones of the mattress by lifting an turning the elongate support elements 38 to expose a firmer or softer face. Labeling or color coding of the faces facilitates the adjustment of the firmness. When the firmness is adjusted as the user desires, the user replaces the pad and the cover, and can use the bed like any conventional bed. When the user desires to adjust the firmness for example because of a weight change or injury, the user simply removes the cover and optional pad, and quickly and easily readjusts the firmness by turning selected ones of the elongate support elements 38. uses the bed,

The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.

Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail. 

What is claimed is:
 1. A mattress assembly comprising: a mattress frame comprising a base surrounded by a sidewall defining a recess, the mattress frame having a head, a foot, and first and second sides extending therebetween; a plurality of elongate support elements disposed in the recess, each of the support elements having at least first and a second faces of different firmness, the elongate support elements arranged in the recess with selected faces oriented upwardly to form an upper mattress surface having a plurality of zones of different surface firmness.
 2. The mattress assembly according to claim 1 wherein all of the elongate support elements are the same size and shape.
 3. The mattress assembly according to claim 1 wherein the elongate support elements are sized and shaped so that there are at least three elongate support elements in series between the head and the foot of the mattress.
 4. The mattress assembly according to claim 3 wherein the elongate support elements are sized and shaped so that there are at least twelve elongate support elements in series between the head and the foot of the mattress.
 5. The mattress assembly according to claim 1 wherein each of the elongate support elements is a rectangular prism, with a rectangular transverse cross section.
 6. The mattress assembly according to claim 5 wherein each of the elongate support elements has a square transverse cross section.
 7. The mattress assembly according to claim 1 wherein each of the elongate support elements comprises at least two foam elements of different firmness forming the at least first and second faces of different firmness.
 8. The mattress assembly according to claim 7 wherein each of the elongate support elements comprises a fluid impermeable envelope surrounding the elongate support element.
 9. The mattress assembly according to claim 8 wherein each of the elongate support elements further comprises at least one vent in the fluid impermeable envelope, to allow air to enter and exit the envelope.
 10. The mattress assembly according to claim 9 wherein the at least one vent is a variable vent, in which the rate of air flow through the vent can be adjusted.
 11. The mattress assembly according to claim 8 wherein each of the elongate support elements further comprises at least one valve in the fluid impermeable envelope, to allow liquid to be introduced into or removed from the envelope.
 12. The mattress assembly according to claim 1 wherein each elongate support element includes compressible foam.
 13. The mattress assembly according to claim 12 wherein each elongate support element includes a liquid.
 14. The mattress assembly according to claim 1 wherein the elongate support elements are arranged in at least two columns, one column adjacent one side of the mattress frame, and another column adjacent the other side of the mattress frame.
 15. The mattress assembly according to claim 1 further comprising a plurality of intermediate elements in the recess below the elongate support elements.
 16. The mattress assembly according to claim 15 wherein at least some of the intermediate elements have different firmnesses.
 17. The mattress assembly according to claim 1 wherein the at least first and second faces of the elongate support elements are marked to distinguish between the relatively firmer and relatively softer faces.
 18. The mattress assembly according to claim 17 wherein the marking to distinguish between the relatively firmer and relatively softer faces comprises color.
 19. The mattress assembly according to claim 1 further comprising a reclosable cover enclosing the mattress frame and the plurality of elongate support elements.
 20. The mattress assembly according to claim 1 further comprising a pad overlying the upper surface formed by the plurality of elongate support elements.
 21. The mattress assembly according to claim 20 further comprising a reclosable cover enclosing the mattress frame, the plurality of elongate support elements, and the pad.
 22. A mattress assembly comprising: a mattress frame comprising a base surrounded by a sidewall defining a recess, the mattress frame having a head, a foot, and first and second sides extending therebetween; a plurality of elongate support elements disposed in the recess, each of the support elements comprising at least two foam elements of different firmness forming at least first and second faces of different firmness, the elongate support elements arranged in the recess with selected faces oriented upwardly to form an upper mattress surface having a plurality of zones of different surface firmness.
 23. The mattress assembly according to claim 22 wherein each of the elongate support elements comprises a fluid impermeable envelope surrounding the elongate support element.
 24. The mattress assembly according to claim 23 wherein each of the elongate support elements further comprises at least one vent in the fluid impermeable envelope, to allow air to enter and exit the envelope.
 25. The mattress assembly according to claim 24 wherein the at least one vent is a variable vent, in which the rate of air flow through the vent can be adjusted.
 26. The mattress assembly according to claim 23 wherein the at least first and second faces of the elongate support elements are marked to distinguish between the relatively firmer and relatively softer faces.
 27. The mattress assembly according to claim 26 wherein the marking to distinguish between the relatively firmer and relatively softer faces comprises color. 